Cornelius ICE FROST User Manual

ICE FROST

Post-Mix and Pre-Mix

Installation, Service, and Operator’s Manual

Release Date: April 19, 2004

Publication Number: M620919596OPR

Revision Date: October 19, 2006

Revision: C

Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

ICE FROST POST-MIX AND PRE-MIX

INSTALLATION, SERVICE, AND

OPERATOR’S MANUAL

The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual.

To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact:

www.cornelius.com

1-800-238-3600

This document contains proprietary information and it may not be

reproduced in any way without permission from Cornelius.

Printed in U.S.A.

TABLE OF CONTENTS

Important Warnings and Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Plate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transportation Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Connecting the Electricity Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Ice Frost Generic (Pre-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Ice Frost Generic (Post-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Bowl Loading Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ice Frost Generic (Pre-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ice Frost Generic (Post-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Brix Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Programming Electronic Touch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

To Enter Time Programming on Initial Installation or in the Event of Service . . . 9

Setting COLD Timer (Night Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Operate in Automatic Mode (with COLD Timer Activated) . . . . . . . . . . . . . . . . 10

Operate in Manual Mode (without COLD Timer Activated) . . . . . . . . . . . . . . . . 10

Setting the 12 or 24 Hour Display and oF or oC Temperature Display . . . . . . 10

Viewing the Bowl Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Consistency Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Quarterly Cleaning and Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Post Mix Systems Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Special Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Restricted Air Flow Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electronic Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electronic Bowl Monitoring and Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure and Level Control Card General Features . . . . . . . . . . . . . . . . . . . . . . . . 17

OFF Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1st Filling Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Managing the Bowl Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Safety Probes (only for Ice Frost Generic Pre-mix) . . . . . . . . . . . . . . . . . . . . . 19

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

VFCB (Pre-Mix) 115V/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

VFCB (Post-Mix) 115V/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

VFCB (Pre-Mix) 230V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

VFCB (Post-Mix) 230V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

IMPORTANT WARNINGS AND ADVICE

This instruction manual represents an integral part of the equipment and must be kept readily available for use.

Read the warnings contained herein carefully before installing and using this equipment.

In addition to offering information concerning routine maintenance for the ice slush drinks machine and technical back-up for troubleshooting, this manual aims to help the user make the most of the machine’s potential, adapting it to suit the specific needs of the various countries it will be used in.

Modifications or attempts to modify the equipment will not only result in the forfeiture of the guarantee, but are also extremely dangerous.

The maintenance operations must be carried out by qualified professionals. Never attempt to repair the machine yourselves as the intervention of non-qualified persons, as well as being hazardous, could also lead to serious damage to the machine.

PLATE DATA

The voltage and the frequency are indicated on the serial number plate, located on the refrigeration deck and the right hand side near the controls.

Ice Frost Operator’s Manual

TECHNICAL DATA

TRANSPORTATION INDICATIONS

To prevent the oil contained in the compressor from flowing out into the cooling circuit, the equipment must be transported, stored, and handled in a vertical position, as per the indications given on the packing.

The wooden pallet, equipped with housing for the lifting forks, allows the packed equipment to be moved using normal handling and hoisting means.

Ice Frost Operator’s Manual

1. Remove the equipment from the packing, then slide it off upwards (see FIGURE 1).

2. Checking the machine identification after removing the packing, you must check that the equipment you have received is exactly as you ordered, making sure the specifications indicated on the invoice or the delivery note are identical to those on the data plate.

INSTALLATION

3. Equipment accessories The following accessories are included inside the bowls:

• This instruction manual;

• 1 tube of Vaseline to be used for the maintenance machine the requires;

• A drip tray.

The back-lit cover is packed separately from the machine.

4. Positioning - make sure the machine’s bodywork is well ventilated, at least 6”, and do not install near heat sources. We recommend you keep the room temperature at between 59 and 77°F.

IMPORTANT: All the pieces of packing must be kept out of reach of children as they represent potential hazards.

5. Remove gear motor shipping pins and tags from the rear of the unit prior to installation.

CONNECTING THE ELECTRICITY MAINS

Before inserting the plug into the mains socket for your own safety you must take careful note of the following precautions.

• The machine’s electrical system can only be considered safe

when it is connected correctly to a grounded outlet, as provided for by the national safety regulations. The manufacturer cannot be held responsible for any damages that may be caused by failure to earth the system.

FIGURE 1

• For the system to be installed correctly and safely, it is

essential to provide a suitable socket having a dedicated 20 Amp circuit which complies with the national safety standards in force (see FIGURE 2).

• Check the power supply cable to make sure it is not being crushed, do not use extension cords and, to

remove the plug, first turn OFF the switch, then hold the plug tightly and pull gently.

• Do not obstruct the ventilation and the heat dissipation grids as bad airing, in addition to reducing the

output and causing bad functioning, could also lead to serious damage to the equipment.

IMPORTANT: If the power supply cord is damaged, it must be replaced by qualified persons only to prevent any possible risks.

FIGURE 2

CONNECTION DIAGRAMS

Ice Frost Generic (Pre-mix)

The diagram shows the sequence for the connection between the ICE FROST GENERIC PRE to an existing pre-mix system.

Ice Frost Operator’s Manual

FIGURE 3

Description:

1. Pre-mix product 1 inlet.

2. Pre-mix product 2 inlet.

Inlet for CO2 (coming from the pressure reducing valve, 12 psi).

5. CO

6. Operating pressure gauge.

8. Gas cylinder pressure gauge.

9. Pre-mix product 1 container.

10. Pre-mix product 2 container.

11. Cooling unit (Optional).

Connection:

Connect the points 1, 2, and 4 on the machine to the existing pre-mix system using quick couplings.

gas cylinder.

CO2 pressure regulator.

Ice Frost Operator’s Manual

Ice Frost Generic (Post-mix)

The diagram shows the sequence for the connection between the ICE FROST GENERIC POST to an existing post-mix system.

FIGURE 4

Description:

1. Syrup 1 inlet.

2. Syrup 2 inlet.

3. Soda water inlet.

Inlet for CO2 45 to 60 psi.

5. CO

gas cylinder.

6. Operating pressure regulator for carbonation unit.

7. Carbonation unit operating pressure gauge.

8. Unit and BIB operating pressure gauges.

9. Pressure regulator.

10. Gas cylinder operating pressure gauge.

11. Water Pressure regulator.

12. Filter.

13. Carbonation unit and optional precooling unit.

14. Syrup 1 pump.

15. Syrup 2 pump.

16. Bag-in-box exchanger.

17. Bag-in-box exchanger.

18. Bag-in-box.

Connection:

Connect the points 1, 2, 3, and 4 on the machine to the existing post-mix system using quick couplings or .265 splice connectors.

Alarms

Ice Frost Operator’s Manual

Safety Probe Alarms (only for ICE FROST GENERIC Pre-mix)

You will remember that the monitoring of the safety probes’ conditions (satisfied/ not satisfied) is only active during the bowl loading phase. It follows, then, that a lack of liquid in the tanks during the non-

loading phases will not be signalled.

When one of the two safety probes fail to detect the flow (presence) of liquid during the loading phase, the system will stop (3-second software filter) the loading phase in progress, while the buzzer on the machine emits an intermittent warning signal lasting 6 seconds.

The fill solenoid connected to the system where the lack of liquid has been detected by the safety probe input can only be energized by switching the system OFF then ON again (cycling power resets fill operation).

If both the safety probes fail to detect a presence of liquid while the bowls are loading, the buzzer on the card will emit an intermittent sound lasting approximately 20 seconds.

The bowl fill solenoids are command (OFF). The normal operation conditions can be restored by switching the machine OFF then ON again using the main switch.

The bowl pressure valve solenoid valve is independent of the alarm signal and continues its CO

gas pressure reading function only.

1st Filling Time-out

A time limit has been set for the first filling phase which is linked to the level probes detection of the presence of liquid.

When one of the two level probes fails to detect the presence of liquid for more than four seconds, the buzzer on the card will emit an intermittent sound for approximately 6 seconds.

The fill solenoid connected to the system where the lack of liquid has been detected by the safety probe input can only be reset by switching the system OFF then ON again.

When both the level probes fail to detect a presence of liquid for more than four seconds, the buzzer on the card emits an intermittent sound lasting approximately 20 seconds.

All the solenoids linked to the system are inhibited (bowl fill and CO The normal operating conditions can be resumed by switching the system OFF and then ON again.

Filling Time-out

A time limit has been set for the normal filling phase which is linked to the level probes SLIV 1 and SLIV 2’s detection of the presence of liquid.

When one of the two level probes fails to detect the presence of liquid for more than one minute, the buzzer on the card will emit an intermittent sound for approximately 6 seconds.

The fill solenoid connected to the system where the lack of liquid has been detected by the safety probe input can only be energized by switching the system OFF then ON again.

When both the level probes fail to detect a presence of liquid for more than on minute, the buzzer on the card emits an intermittent sound lasting approximately 20 seconds.

gas management valves = OFF).

The bowl fill solenoids are command (OFF). The normal operating conditions can only be resumed by switching the system OFF and then ON again.

The CO2 gas management valve solenoid valve is independent of the alarm signal and continues its CO

gas pressure reading function only (see relevant paragraph).

Ice Frost Operator’s Manual

“FILTER CLEANING” Alarm

A filter cleaning alarm will activate when the unit is running hot due to insufficient internal air circulation. When this occurs a “Filtr” message will appear on the touch pad LED display readout and an intermittent tone will also sound to alert the operator of this condition.

The “Filtr” message will appear when the alarm activates (a beeping sound every 4-5 seconds). To determine the condition that caused the alarm and correct problem, see list of conditions below:

Condition Corrective Action

• The filter is dirty and needs to be cleaned. • Clean and replace filter following instructions

• The unit is positioned too close to a wall or

other object restricting air flow and causing the machine to run at a higher temperature.

• The filter is not properly installed. • Properly install filter (Removing and cleaning fil-

• The unit has been installed near a heat

source, such as a coffee machine, ice maker or cold beverage machine which expels hot air from its vents, causing the machine to run at a high temperature (installation near a heat source should be avoided).

“SYSTEM OVER TEMPERATURE” Alarm

A system over temperature alarm will activate as a safety precaution when the unit has overheated to protect the compressor.

• The system automatically goes to “OFF” status where the compressor’s operations is stopped, while

augers will keep working to avoid forming ice blocks.

(Removing and Cleaning Filter).

• Reposition unit to maximize ventilation space (Installation Instructions).

ter).

• Reposition unit to maximize ventilation space.

• When this occurs an “Err” message will appear on the touch pad LED readout accompanied by a

continuous buzzer sound to alert the operator of this condition.

• When this alarm sounds, turn OFF all switches. Then determine the reason for the alarm. (See “Filter

Cleaning” Alarm Section for Conditions and Corrective Actions).

+ 22 hidden pages

Cornelius ICE FROST User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual